Archie Pytches

Product Design

He/Him

I'm a confident and creative product designer and patent-pending inventor (GB2512785.3) with passion for exploring what AI means for the future of design. Outside the studio I sing in a jazz band and am learning to stay dry whilst kayaking.

Generative Design Study For FPV Drone Bodies

Using Fusion 360’s generative design tool, this project developed a structurally optimised body for a 3-inch FPV drone. By defining preserve and avoidance geometry, applying real-world motor forces, and specifying 3D printing constraints, the software produced an organic lattice frame in PLA achieving a safety factor of 343, far exceeding the minimum requirement of 2, at a material cost of just £2.44.

Define the Geometry

Set up the preserved geometry (motor mounts, battery holder, landing gear) and avoidance zones that the design must work around, then apply the real-world forces acting on each mount point.

Run the Generative Study

Specify the material (PLA), manufacturing method (FDM additive), and objectives (safety factor 2.0, modal frequency 150Hz), then let Fusion 360 generate and compare multiple design outcomes across different materials simultaneously.

Refine for Manufacture

Select the best performing outcome and use an LLM-generated Fusion 360 plugin to analyse overhangs and automatically add print supports, optimising the design for FDM 3D printing.

Automated Injection Moulding Mould Tool Generation

Exploring whether an injection mould tool could be created using LLMs directly within Fusion 360 using Fusion API scripts. A custom add-in was developed that generates a two-part mould block with draft angles, alignment pins, and a runner system from any uploaded STEP file, enabling a rapid pathway from generative design output to mass-manufacturable tooling.

Following submission in May, the mould tool generation workflow has been rebuilt in Rhino Grasshopper, addressing the limitations of Fusion 360’s Python API and enabling a more robust, parametric approach to automated tooling.

Generate the Initial Mould Block
A Python script was used by an LLM as a Fusion 360 add-in to automatically create a two-part mould block around the drone body, complete with alignment pins, draft angles, and a cavity from the drone’s geometry.
Develop the Conformal Parting Surface
To handle the drone’s complex overhanging geometry, a novel ray casting approach was explored.
Points are projected above and below the part to create a parting surface that contours the shape of the drone rather than using a flat split plane.
Add Inserts for Complex Geometry
Because overhanging features cannot be released from a simple two-part tool, the add-in was developed further to automatically generate mould inserts, allowing more complex undercut geometry to be produced and removed from the block.
Rebuilt in Rhino Grasshopper
Recognising the limitations of Fusion’s poorly documented API, the workflow was migrated to Rhino Grasshopper, enabling direct silhouette extraction, native “up to next” projection, and a proper AI feedback loop for more reliable and accurate mould tool generation.

Spine Align

Supporting lifeguards in recovering Casualties with spinal injuries from deep or complex water scenarios.

The Problem

Cervical spinal injuries account for 60% of all spinal injuries and are among the most life-altering emergencies lifeguards face. Currently, there is no RLSS-recommended extraction method for casualties with suspected spinal injuries in deep water. Casualties must first be moved to shallow water before a spinal board can be deployed, adding critical minutes to a rescue.

Casualty with a suspected C Spine Injury is spotted by lifeguards
‘Spine-Align’ is applied to the casualty
The CO2 release cord is pulled and the device inflates

The Solution

Spine-Align is a CO₂-inflated cervical stabilisation device designed to be deployed by a single lifeguard in deep water in under 10 seconds. Two buoyant polymer shells, connected by neodymium magnets, are placed around the casualty’s neck and inflated via a pull-cord mechanism — providing inline spinal stabilisation while supporting the casualty’s head above water and freeing the lifeguard’s hands.

User Testing

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